In 2021, we installed a new 35 kW air compressor while keeping the two old 30 kW compressors as backups to reduce energy consumption. This initiative has increased the plant’s efficiency, as the new compressed air line ensures stable air pressure in the production environment.
The new plant replaces systems that were at the end of their useful life and no longer met energy efficiency requirements.
Key Results
Adjustments & Implementation
The upgraded compressors play an important role in maintaining a stable production environment with reduced energy consumption, enhancing the plant’s sustainability.
In line with our goals to reduce energy consumption, we have implemented measures to reduce the electricity consumption of the pre-drying deck significantly.
The pre-drying deck, which accounts for 17% of total electricity consumption, has been identified as the second largest electricity consumer in the plant.
Transitioning to energy-efficient pre-drying
The topside pre-drying utilizes infrared lamps, which consume substantial energy, while the bottomside pre-drying uses ceramic elements, consuming significantly less power.
Step-by-step implementation
Between 2020 and 2022, line trials were conducted to determine if using only the bottom-side pre-drying would result in a loss of quality.
Various product surfaces, such as whiteboards, chalkboards, and infrastructure products, were tested and approved for use with only the bottom-side pre-drying.
Results
By utilizing only the bottom-side pre-drying, we achieved a 40% reduction in electricity consumption, decreasing daily consumption from 1493 kWh to 898 kWh.
This measure led to a broader reduction in electricity consumption per m² of coil line, which was 22% lower in 2021 than in 2020.
As part of SDG 7, we completely renovated the lighting in four production halls (Halls 1, 2, 3, and 4).
This project aimed to reduce energy consumption and improve working conditions by switching from fluorescent lighting to energy-efficient LED lighting. This modernization contributed to significant energy savings and improved lighting levels for employees.
Analysis of the current situation
During the analysis, it was found that the old lighting (fluorescent lighting) was on continuously, leading to significant energy consumption. In Hall 1, the lighting was on 24 hours a day, while in the other halls, it was on for an average of 18 hours a day. The light level, about 150 lux, was considered far too low for the production environment.
Motion sensors
Sixty motion sensors were installed to reduce unnecessary energy consumption. Lighting is automatically turned on when activity is detected and turned off when not needed.
Automatic daylight dimming
Hall 3 and Hall 4 have installed an automatic daylight dimming system. This ensures that the lighting automatically dims when sufficient natural light is present.
DALI control
The lighting in all halls is equipped with DALI control, which means that each lighting fixture can be controlled individually or in groups. This can be easily managed via an iPad provided, offering flexibility and efficiency in adjusting light levels on the shop floor.
Project Implementation
This large-scale renovation has resulted in significant energy savings, better working conditions through increased light levels, and modern, efficient lighting control. Implementing sensors and daylight control ensures that energy consumption is much more efficient.
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